Multi-functional sunroof assembly bracket endcap and deflector protector

The subject matter described herein relates, in general, to sunroof assemblies and, more particularly, to bracket endcaps and deflector protectors for sunroof assemblies.

In some vehicles, sunroof assemblies include sunroof panels that open and close a sunroof opening in a roof of the vehicle. In some instances, sunroof panels are constructed from glass, allowing a passenger of the vehicle to see through the sunroof opening when the sunroof panel closes the sunroof opening. While glass provides transparency, it may flex under wind pressure as the vehicle travels forward. Accordingly, some vehicles include a bracket connected to the sunroof panel that extends laterally with respect to the vehicle and provides additional strength and rigidity to the sunroof panel. In some instances, the bracket is hollow, and the sunroof assembly additionally includes endcaps to close the bracket on either end.

In some vehicles, sunroof assemblies also include a deflector for diffusing high-pressure air traveling over the vehicle when the sunroof assembly is open. In some arrangements, the deflector includes a spring-loaded deflector arm and a mesh connected to the deflector arm and one or more other components of the sunroof assembly. In some arrangements, the deflector is stored under a sunroof panel of the sunroof assembly. As the sunroof panel moves to an open position, the sunroof panel retracts and allows the spring-loaded deflector arm to rise above the vehicle and stretch the mesh such that it is taut and functional to diffuse high-pressure air. Contrariwise, as the sunroof assembly moves to a closed position, the sunroof panel pushes the spring-loaded deflector arm down such that it is in a stowed position within the sunroof assembly. In some arrangements, contact between the sunroof panel and the deflector arm may cause damage to the sunroof panel and/or the deflector arm. Moreover, in some arrangements, the respective positions of the sunroof panel and the deflector arm during closing of the sunroof assembly may provide sub-optimal mechanical advantage to push the deflector arm to the stowed position. Accordingly, some sunroof assemblies include deflector protectors, which may be attached to the sunroof panel.

In vehicles that include both a bracket and a deflector, the sunroof assembly may include endcaps and deflector protectors that are both connected to the sunroof panel. In such instances, the use of both endcaps and deflector protectors requires the use of many additional fasteners for connecting the components to the sunroof panel and may increase the overall weight and cost of the sunroof assembly.

In one embodiment, example systems relate to multifunctional bracket endcaps and deflector protectors for sunroof assemblies. In the embodiment described herein, a sunroof assembly includes a sunroof panel that opens and closes a sunroof opening of a vehicle. In some arrangements, the sunroof panel is constructed from glass, which may flex under wind pressure as the vehicle travels forward. Accordingly, in one arrangement, the sunroof assembly includes a bracket that is connected to the sunroof panel, extends laterally with respect to the vehicle, and provides additional strength and rigidity to the sunroof panel. In some instances, the bracket is bonded to the sunroof panel in a molding process in which the components of the sunroof assembly are loaded into a mold into which encapsulation material is inserted. In some instances, during the molding process, the bracket is hollow and encapsulation material may enter the bracket, which may increase the overall weight of the sunroof assembly. Accordingly, in one arrangement, the sunroof assembly also includes endcaps for closing off the hollow bracket during the molding process.

For multifunctionality and to reduce the overall number of components of the sunroof assembly, in one or more arrangements, the endcaps have a geometry that enables the endcaps to additionally function as deflector protectors. Accordingly, in one approach, the endcaps include endcap points, which are rounded points configured to contact deflector arms of a deflector of the sunroof assembly. In this way, in one approach, the endcaps contact the deflector arms, which may be spring-loaded, to prevent damage to the deflector arms, the encapsulation material, and/or the sunroof panel by maintaining clearance between the sunroof panel and the deflector arms. Moreover, in one arrangement and by way of contacting the deflector arms, the endcaps also serve to provide mechanical advantage to push the deflector arms to a stowed position as the sunroof panel closes the sunroof opening and inhibit rapid movement of the deflector arms from the stowed position as the sunroof panel opens the sunroof opening.

Accordingly, the arrangements described herein have the benefit of providing multifunctional bracket endcaps and deflector protectors for sunroof assemblies. As such, the sunroof assembly requires fewer parts than typical sunroof assemblies, which may provide bracket endcaps and deflector protectors as separate components. Moreover, the use of the endcaps as described herein decreases the number of fasteners required with the use of separate bracket endcaps and deflector protectors. Furthermore, by way of requiring fewer parts, the arrangements described herein also have the benefits of streamlining the sunroof assembly manufacturing process, improving the packaging of the sunroof assembly, and decreasing the total cost of the sunroof assembly. Moreover, the arrangements described herein have the benefit of reducing the risk of damage to the components of the sunroof assembly, including the sunroof panel, the encapsulation material, and the deflector arms, as well as providing the mechanical advantage necessary to stow the deflector as the sunroof panel moves to the closed position.

In one embodiment, a sunroof assembly includes a bracket removably attached to a sunroof panel and defining a cavity. The sunroof assembly also includes an endcap removably attached to the bracket that closes the cavity and maintains clearance between the sunroof panel and a deflector of the sunroof assembly by contacting the deflector as the sunroof panel moves between an open position, in which the deflector is in a raised position, and a closed position, in which the deflector is in a stowed position.

In another embodiment, a sunroof assembly includes a sunroof panel defining a sunroof panel edge lined with encapsulation material installed to the sunroof panel edge in a molding process. The sunroof assembly also includes a bracket removably attached to a sunroof panel and defining a cavity. The sunroof assembly further includes an endcap removably attached to the bracket that prevents encapsulation material from entering the cavity during the molding process by closing the cavity and that maintains clearance between a deflector of the sunroof assembly and the encapsulation material and prevents damage to the encapsulation material by contacting the deflector as the sunroof panel moves between an open position, in which the deflector is in a raised position, and a closed position, in which the deflector is in a stowed position.

In yet another embodiment, a sunroof assembly includes a sunroof panel defining a first corner and a second corner. The sunroof assembly also includes a bracket removably attached to the sunroof panel that extends between the first corner and the second corner and defines a cavity having a first opening below the first corner and a second opening below the second corner. The sunroof assembly also includes a deflector located below the sunroof panel and defining a first deflector arm located below the first corner and a second deflector arm located below the second corner. The sunroof assembly also includes a first endcap removably attached to the bracket at the first opening and a second endcap removably attached to the bracket at the second opening. The first endcap and the second endcap maintain clearance between the sunroof panel and the deflector by respectively contacting the first deflector arm and the second deflector arm as the sunroof panel moves between an open position, in which the deflector is in a raised position, and a closed position, in which the deflector is in a stowed position.

Systems and other embodiments associated with a deflector protector for a sunroof assembly are disclosed. As mentioned above, in vehicles that include both a bracket and a deflector, the sunroof assembly may include bracket endcaps and deflector protectors that are both connected to the sunroof panel. In such arrangements, the use of both endcaps and deflector protectors requires the use of many additional fasteners for connecting the components to the sunroof panel and may increase the overall weight and cost of the sunroof assembly. Accordingly, the arrangements described herein provide multifunctional bracket endcaps and deflector protectors for a sunroof assembly that eliminate the need for separate bracket endcaps and deflector protectors. As a result, through use of the bracket endcaps, the sunroof assembly has fewer parts, lower cost, and a more streamlined assembly process than other sunroof assemblies.

In one example, multifunctional bracket endcaps and deflector protectors for sunroof assemblies are disclosed. In some vehicles, a sunroof assembly includes a sunroof panel that opens and closes a sunroof opening in the vehicle. The sunroof panel is constructed from glass in some arrangements, which sometimes flexes under wind pressure as the vehicle moves forward. To strengthen and rigidify the sunroof panel, the sunroof assembly includes a bracket connected to the sunroof panel. The bracket is formed, in one example, from a high-strength material such as metal, and is hollow for the purpose of lightweighting the sunroof assembly. In one arrangement, the bracket is connected to the sunroof panel in a lateral direction with respect to the vehicle.

To connect the bracket to the sunroof panel, in one approach, the bracket and the sunroof panel are bonded to each other in a molding process. During the molding process, the components of the sunroof assembly are placed in a mold, and encapsulation material is added to the mold. In some instances, during the molding process, encapsulation material may enter the hollow bracket, which may increase the overall weight of the sunroof assembly. Accordingly, in one arrangement, the sunroof assembly includes endcaps for closing off the bracket to prevent encapsulation material from entering the bracket.

The endcaps additionally function as deflector protectors. As mentioned above, the sunroof assembly includes a deflector that has spring-loaded deflector arms that bias the deflector to a raised position. To function as deflector protectors, in one arrangement, the endcaps include rounded points that contact the deflector arms to prevent damage to the deflector arms, the encapsulation material, and/or the sunroof panel by maintaining clearance between the sunroof panel and the deflector arms. Moreover, in one arrangement, the endcaps also provide mechanical advantage to push the deflector arms to a stowed position as the sunroof panel closes the sunroof opening and/or inhibit rapid movement of the deflector arms from the stowed position as the sunroof panel opens the sunroof opening.

Accordingly, the arrangements described herein advantageously provide multifunctional bracket endcaps and deflector protectors for sunroof assemblies. By way of the multifunctionality of the endcaps, the sunroof assembly requires fewer parts than typical sunroof assemblies that have separate bracket endcaps and deflector protectors. Moreover, the arrangements herein require the use of fewer fasteners compared to sunroof assemblies that have separate bracket endcaps and deflector protectors. Furthermore, as a result of fewer components, the arrangements described herein also have the benefit of streamlining the sunroof assembly manufacturing process, improving the packaging of the sunroof assembly, and decreasing the total cost and/or weight of the sunroof assembly. The multifunctional endcaps also help prevent damage to the components of the sunroof assembly and provide the mechanical advantage necessary to stow the deflector as the sunroof panel closes the sunroof opening.

Part of a representative passenger vehicleis shown in. The vehicleincludes an exterior and a number of interior compartments. In one arrangement, the vehicleincludes a body that forms the exterior and defines or otherwise encloses the compartments. In some instances, the body includes a first sideA, a second sideB, a horizontal roof, a floor, a front end, a rear end, and the like. In one example, the body is constructed from a combination of rigidly interconnected frame members, panels, and other body elements, as well as a combination of overlying paneling, trim, upholstery, and other body coverings. In some instances, the body elements have a combination of fabricated, bent, stamped, extruded, cast, molded and like constructions, and are made from a combination of metallic, polymeric and like materials.

The roofextends laterally between the first sideA and the second sideB. As part of the roof, the body includes a sunroof opening that opens between the passenger compartment and the exterior. Moreover, in one arrangement, the body includes a roof panel that defines the sunroof opening. Moreover, in some instances, the body includes a pair of roof rails and, as part of the roof panel, a roof header, that frame the sunroof opening. In one arrangement, the roof rails are laterally spaced apart from one another about the sunroof opening and extend longitudinally. In one example, the roof panel extends longitudinally from the roof header, and laterally between the roof rails. In one arrangement, the roof header is forward of the sunroof opening and extends laterally between the roof rails. In an assembled state, in some instances, the roof rails, the roof panel, and the roof header are secured to one another. In one arrangement, the roof panel, including the roof header, is secured to the roof rails along its length. In one example, the roof header, as part of the roof panel, is secured to the roof rails at its ends.

In some arrangements, the vehicleincludes a sunroof assemblythat is installed to the sunroof opening. Among other components typical of sunroof assemblies, in some arrangements, the sunroof assemblyincludes a sunroof panelthat extends between the first sideA and the second sideB and opens and closes the sunroof opening. When the sunroof assemblyis in an open position, as shown in, the sunroof panelopens the sunroof opening, and in a closed position, the sunroof panelcloses the sunroof opening. The sunroof panelcan be made from a material suitable for closing the passenger compartment from an external environment of the vehiclewhile allowing a passenger in the vehicleto see through the sunroof panelwhen the sunroof panelis in the closed position. In one example, the sunroof panelis made of glass, but in other examples, the sunroof panelcan be made of one or more other suitable materials. Although the sunroof assembly, as shown, includes one sunroof panel, this disclosure is applicable in principle to otherwise similar vehicles whose sunroof assemblies include multiple sunroof panels. The sunroof assemblyalso includes one or more sunshades and driving equipment for moving the sunroof panelthat moves the sunroof paneland/or the sunshades between the open position and the closed position.

The sunroof assemblyalso includes a housingthat houses various components of the sunroof assemblyand supports the components for attachment to the vehicle. In one arrangement, the housingis attached to the roof header and/or other components of the vehicle and is located within the sunroof opening. To fit to the sunroof opening, in one example, the housinghas a shape that substantially matches the shape of the sunroof opening. More specifically, in one example, the housinghas curved corners including a first front cornerA and a second front cornerB that align with the shape of the sunroof opening. While the remainder of this disclosure is described with reference to the first front cornerA, in some instances, the description herein also applies to the second front cornerB.

Among the components supported by the housing, the sunroof assemblyincludes a deflector. As shown, in one example, the deflectorincludes a first deflector armA and a first deflector armB each hingedly connected to the housingon opposite sides of the sunroof assembly. In some instances, the first deflector armA and the second deflector armB are spring-loaded in a manner that is biased towards a raised position above the sunroof assembly, as shown in. When the sunroof assemblyis installed to the sunroof opening, in one arrangement, the first deflector armA is located above the first front cornerA, and the first deflector armB is located above the first front cornerA. In the embodiment shown, the first deflector armA and the first deflector armB are formed as a unitary component. However, in other embodiments, the first deflector armA and the first deflector armB are formed as separate components that are later connected together.

In addition to the first deflector armA and the second deflector armB, the deflectoralso includes a meshconnected to the first deflector armA, the first deflector armB, and the housingBy way of being spring-loaded, in one arrangement, the first deflector armA and the first deflector armB are arranged to expand the meshabove the housingwhen the sunroof assemblyis in the open position and retract the meshunder the sunroof panelwhen the sunroof assemblyis in the closed position. When the sunroof assemblyis in the open position and as the vehicletravels in a forward direction, the meshis stretched to a tautness such that the meshdirects airflow over the sunroof opening and diffuses high pressure air in such a way as to reduce wind noise and turbulent airflow into the passenger compartment. Contrariwise, when the sunroof assemblyis in the closed position, the deflectoris stowed in the housing.

As mentioned above, when the sunroof assemblyis in the open position or the closed position, the sunroof panelmay flex due to wind pressure as the vehicletravels forward. Flexing of the sunroof panel, in some instances, is caused by flexibility of the material that the sunroof panel. For example, in some arrangements, the sunroof panelis made of glass that is flexible in the Z-direction with respect to the vehicle. In some instances, wind pressure may become so great that the sunroof panelover-flexes and shatters. Accordingly, to provide strength to the sunroof paneland mitigate flexing of the sunroof panel, in one or more arrangements, the sunroof assemblyincludes a bracket. The bracket, in one approach, is connected to the sunroof paneland made from a high-strength material to impart rigidity to the sunroof panel.

An example of the bracketis shown in. In one arrangement, the bracketis attached to an underside of the sunroof panel, as shown inand described in further detail below. When attached to the sunroof panel, in one example, the bracketextends laterally across the sunroof panelwith respect to the X-direction of the vehicle. In one arrangement, the bracketis positioned towards the forward end of the vehiclenear the housingand defines a first bracket endA located at or near the first front cornerA and a second bracket endB located at or near the second front cornerB. Moreover, in some arrangements, the first bracket endA is located above the first deflector armA and the second bracket endB is located above the first deflector armB.

As mentioned above, the bracketis formed from a high-strength material. In one approach, the bracketis made of metal using a roll-forming process, which is a continuous process that converts sheet metal into an engineered shape using consecutive sets of mated rolls, each of which makes incremental changes in the form such that the sum of the incremental changes is a complex profile. Accordingly, in one arrangement, the bracketis a roll-formed bracket. However, in other approaches, the bracketis made from other types of manufacturing processes, for example, an extrusion process. Moreover, as mentioned above, the bracketis formed of metal, however, in other examples, the bracketis formed from other materials suitable for imparting strength and rigidity to the sunroof panel.

As described in further detail below, in one or more arrangements, the first bracket endA and/or the second bracket endB may be hollow. In such arrangements, the sunroof assemblyalso includes one or more endcaps fitted to the bracketto close the first bracket endA and/or the second bracket endB. In the example shown, the sunroof assemblyincludes a first endcapA and a second endcapB respectively installed to the first bracket endA and the second bracket endB. In some instances, the first endcapA and the second endcapB are substantially identical in one or more aspects, while in other instances, the first endcapA and the second endcapB are different from each other in one or more aspects. In one approach, the endcapsA,B are installed to the bracketbefore the bracketis placed on the sunroof panelfor later attachment to the sunroof panel. In addition to closing the first bracket endA and/or the second bracket endB, the endcapsA,B serve various other purposes for the sunroof assemblythat are described in further detail below.

As mentioned briefly above, the bracketis attached to the sunroof panel. Additionally, the endcapsA,B are also connected to the sunroof panelin conjunction with the attachment of the bracketto the sunroof panel. With reference now to, in one or more arrangements, the sunroof assemblyincludes an encapsulationthat attaches the bracketand the endcapsA,B to the sunroof panel. More specifically, in one example, the encapsulationbonds the bracketand the endcapsA,B to the sunroof panel. In some instances, as described in further detail below, the encapsulationalso lines an edge of the sunroof panelto protect the edge of the sunroof panelfrom damage.

In an example method of attaching the bracket, the endcapsA,B, and the sunroof panel, the endcapsA,B are first installed to the bracket, and the brackettogether with the endcapsA,B is set on the sunroof panel. Next, in one approach, the sunroof paneltogether with the bracketand the endcapsA,B is inserted into a mold. The mold, in one example, has the appropriate shape for the encapsulation, including the contours of the bracket, the endcapsA,B, the sunroof panel, and/or other components of the sunroof assembly. In a next phase of the method, in one approach, encapsulation material is inserted into the mold in liquid form. In other words, the sunroof panel, the bracket, and the endcapsA,B are bonded in a molding process. Once cured, in some examples, through the application of heat, the encapsulation material bonds the sunroof panelto the bracketand the endcapsA,B. In some arrangements, the encapsulationmay be additionally secured to the components of the sunroof assemblyusing fasteners. Accordingly, the encapsulationincludes aperturesthat substantially align with apertures in the bracketand/or the endcapsA,B that receive the fasteners for further securing the components of the sunroof assembly.

The encapsulation material, in one example, is a material suitable for bonding the sunroof panelto the bracketand the endcapsA,B. In one example, the encapsulation material is polyurethane, but the encapsulation material can be other materials, for example, other thermoplastic materials. Moreover, the molding process is, in some approaches, a reaction-injection molding (RIM) process, but in other approaches, the molding process is another type of molding process, for example, another type of injection molding process. Moreover, the components of the sunroof assemblydescribed above, including the bracket, the endcapsA,B, and the encapsulation, are removably attached to the sunroof panel. For example, the bracketand/or the endcapsA,B may be removed from the sunroof panelafter removal of the encapsulation.

As mentioned above, the first bracket endA and/or the second bracket endB may be hollow. In fact, in some arrangements, the entire bracketis hollow. Use of a hollow bracket is, in one or more arrangements, advantageous for lightweighting the sunroof assembly. As mentioned above, during the molding process, the endcapsA,B serve to close off the ends of the bracketso that the encapsulation material does not enter the bracket. In some instances, it is advantageous to prevent the encapsulation material from entering the bracketso that the bracketand the rest of the sunroof assemblydo not have an increased weight from unnecessary encapsulation material in the bracket.

Referring now to, the bracketdefines a cavity. The cavity, in one example, extends from the first bracket endA to the second bracket endB. Thus, in one arrangement, as mentioned above, the bracketis hollow along its entire length, and the cavityextends along the entire length of the bracket. In other arrangements, the cavitymay not extend along the entire length of the bracket. For example, the bracketmay be hollow at the first bracket endA or the second bracket endB, and thus the cavitymay be limited to the first bracket endA or the second bracket endB. In another example, the bracketmay be hollow at both the first bracket endA or the second bracket endB and not hollow in a middle area along the bracket. In the embodiment described herein, the bracketis hollow along its entire length and the cavityextends along the entire length of the bracket. In embodiments in which the bracketis only hollow on one side, a single endcap may be used to close the cavity. Moreover, while the remainder of this description references the first endcapA, in some instances, the description also applies to the second endcapB in one or more aspects.

An example of the installation of the first endcapA to the cavityis shown. In some instances, the following description applies to the second endcapB as well. In some arrangements, for installation to the bracket, the first endcapA includes legs. The legs function to align the first endcapA with the bracketduring installation of the first endcapA to the bracket. As shown, the first endcapA includes three legs including a first legA, a second legB, and a third legC, however, the first endcapA can include another number of legs suitable for installing the first endcapA to the bracket. In one approach, the legsA,B, andC are inserted into the cavityfor installing the first endcapA to the bracket. In some arrangements, for example, as shown, the location of the legsA,B, andC corresponds to one or more contours of the cavity. For example, the cavitymay define a narrow contourand a wide contour. In one arrangement, for example, in the embodiment shown, the first legA is wider than the second legB and the third legC and is installed to the narrow contour. Moreover, in one arrangement, the second legB and the third legC are thinner than the first legA and are installed to opposite sides of the wide contour. Accordingly, in one arrangement, the legsA,B, andC have a shape corresponding to the contours of the cavity, and by way of installation to the cavity, the legsA,B, andC maintain the position of the first endcapA relative to the bracket.

In some arrangements, the legsA,B, andC secure the first endcapA to the bracket. However, for additional security of the first endcapA to the bracket, in some arrangements, one or more of the legsA,B, andC includes a ridge. As shown, the first legA includes a ridge, but in other arrangements, one or more of the first legA, the second legB, and the third legC can include a ridge. In some examples, the ridgepressure-fits the legsA,B, andC to the contours of the cavityto help prevent the first endcapA from coming loose from the cavity. Like other components of the sunroof assembly, in some instances, the first endcapA is removably attached to the bracket.

In addition to the legsA,B,C, the first endcapA also includes a base. In one example, the baseis a flat portion of the first endcapA that is substantially flush with the sunroof panelwhen the first endcapA is bonded to the sunroof panel. In some arrangements, the basefunctions to secure the first endcapA to the sunroof panelduring the encapsulationprocess. For example, the encapsulation material overlies the base(as shown in) and secures the first endcapA to the sunroof panel. Moreover, in addition to the legsA,B,C and the base, the first endcapA also includes, in some arrangements, an endcap point. In one example, the endcap pointis a portion of the first endcapA that rises above the bracket. As described in further detail below, the endcap pointof the first endcapA contacts the first deflector armA. Similarly, in some instances, the second endcapB also includes an endcap pointthat contacts the second deflector armB, as described in further detail below. In some instances, the endcap pointof the first endcapA is rounded so that the first endcapA has the ability to slide in a smooth manner along the first deflector armA. In this way, as described in further detail below, the first endcapA serves as a deflector protector for the sunroof assembly.

In some arrangements, the components of the first endcapA, including the legsA,B, andC, the ridge, the base, and the endcap point, are made from the same material. For example, the legsA,B, andC, the ridge, the base, and the endcap pointare made from plastic. In another example, the legsA,B, andC, the ridge, the base, and the endcap pointare made from another material, such as a thermoplastic. In some arrangements, the legsA,B, andC, the ridge, the base, and/or the endcap pointare made from different materials. Moreover, in one arrangement, the legsA,B, andC, the ridge, the base, and/or the endcap pointare formed unitarily as a single component. For example, the legsA,B, andC, the ridge, the base, and/or the endcap pointare formed unitarily using a molding process, such as an injection molding process, a casting process, or a 3D printing process. In other arrangements, the legsA,B, andC, the ridge, the base, and/or the endcap pointare formed as separate components that are later connected to each other.

By way of being manufactured components, in some arrangements, the aforementioned components of the first endcapA and/or the bracketmay include standard defects from manufacturing processes. For example, the metal of the bracketmay contain burrs. In some instances, such defects may contact the sunroof panel, thereby damaging the sunroof paneland/or weakening the sunroof panel. Thus, in some instances, it may be advantageous to space the first endcapA and/or the bracketfrom the sunroof panelor decrease the amount of surface area of the first endcapA and/or the bracketthat contact the sunroof panelto decrease the likelihood of a defect contacting and damaging the sunroof panel.

Accordingly, referring now toB, andC, the first endcapA and/or the bracketmay include spacers. More specifically, in one example, the first endcapA includes endcap spacers. In one arrangement, the endcap spacersspace the basefrom the sunroof paneland decrease the surface area of the basethat contacts the sunroof panel. As shown, the endcap spacershave substantially conical shapes with rounded tips, which improve the contact between the endcap spacersand the sunroof panel. However, in other arrangements, the endcap spacershave one or more other shapes. Moreover, while the figures show the endcap spacersas each having substantially the same shape, in other instances, one or more of the endcap spacershave different shapes.

In one arrangement, the endcap spacersspace the basefrom the sunroof panelby about 1 millimeter (mm). However, other spacings are possible, for example, about 0.5 mm, about 2 mm, about 5 mm, etc. Additionally, in one approach, the endcap spacersare unitarily formed with the first endcapA as a single component, and in another approach, the endcap spacersare formed as separate components from the first endcapA that are later attached to the base, for example, by adhesion and/or fasteners. Moreover, in one approach, the endcap spacersare formed from the same material as the first endcapA, for example, plastic or thermoplastic, while in another approach, the endcap spacersare formed from a different material from the first endcapA, for example, foam, rubber, etc.

In some arrangements, the spacers also include bracket spacers. In one arrangement, the bracket spacersspace the bracketfrom the sunroof paneland decrease the surface area of the bracketthat contacts the sunroof panel. As shown, the bracket spacershave substantially rectangular shapes with a flat surface. However, in other arrangements, the bracket spacershave one or more other shapes. In one arrangement, the bracket spacersspace the bracketfrom the sunroof panelby about 1 millimeter (mm), however, other spacings are possible, for example, about 0.5 mm, about 2 mm, about 5 mm, etc. Additionally, in one approach, the bracket spacersare unitarily formed with the bracketas a single component, and in another approach, the bracket spacersare formed as separate components from the bracketthat are later attached to the bracket, for example, by adhesion and/or fasteners. In one approach, the bracket spacersare formed from a material softer than the material of the bracket, for example, plastic, foam, rubber, etc.

As mentioned above, the first endcapA functions as a deflector protector for the sunroof assembly.and SB illustrate examples of the first endcapA contacting the deflectorto function as a deflector protector. By way of contacting the deflector, in some instances, the deflector protector protects the encapsulation material along an edgeof the sunroof panel. More specifically, in one example, the first endcapA contacts the first deflector armA as the sunroof panelmoves from an open position to a closed position or from a closed position to an open position.illustrates an example of the sunroof panelin a partially closed position (e.g., moving from the open position to a closed position or moving from the closed position to an open position), andillustrates the sunroof panelin a closed position. As shown in, the first endcapA contacts the first deflector armA in the partially closed position. More specifically, the first endcapA point slides along the first deflector armA in the partially closed position. In this way, the first endcapA maintains clearance between the first deflector armA and the sunroof paneland/or the encapsulationduring movement of the sunroof panel, thus preventing damage to the sunroof panel, the encapsulation material on the edge, and/or the first deflector armA. Moreover, as the sunroof panelmoves from an open position to a closed position, the first endcapA provides mechanical advantage to push the first deflector armA from a raised position to a stowed position. As the sunroof panelmoves from a closed position to an open position, the first endcapA inhibits rapid movement of the first deflector armA from a stowed position to a raised position. Referring now to, when the sunroof panelis in a closed position, the first endcapA contacts the first deflector armA to keep the first deflector armA in a stowed position.

In arrangements in which the sunroof assemblyincludes a first endcapA and a second endcapB, the first endcapA and the second endcapB respectively maintain clearance between the first deflector armA and the second deflector armB, as well as the sunroof paneland/or the encapsulationduring movement of the sunroof panel, thus preventing damage to the sunroof panel, the encapsulation material on the edge, the first deflector armA, and/or the second deflector armB. Moreover, as the sunroof panelmoves from an open position to a closed position, the first endcapA and the second endcapB provide mechanical advantage to respectively push the first deflector armA and the second deflector armB from a raised position to a stowed position. Further, as the sunroof panelmoves from a closed position to an open position, the first endcapA and the second endcapB respectively inhibit rapid movement of the first deflector armA and the second deflector armB from a stowed position to a raised position. Additionally, when the sunroof panel is in a closed position, the first endcapA and the second endcapB respectively contact the first deflector armA and the second deflector armB to keep the deflectorin a stowed position.

The arrangements described herein have the benefit of providing a deflector protector for a sunroof assembly using fewer parts than typical sunroof assemblies, which may provide bracket endcaps and deflector protectors as separate components. Moreover, the use of the endcaps as described herein decreases the number of fasteners required with the use of separate bracket endcaps and deflector protectors. Furthermore, by way of requiring fewer parts, the arrangements described herein also have the benefits of streamlining the sunroof assembly manufacturing process, improving the packaging of the sunroof assembly, and decreasing the total cost of the sunroof assembly. Moreover, the arrangements described herein have the benefit of reducing the risk of damage to the components of the sunroof assembly, including the sunroof panel, the encapsulation material, and the deflector, as well as providing the mechanical advantage necessary to stow the deflector as the sunroof panel moves to the closed position.

Detailed embodiments are disclosed herein. However, it is to be understood that the disclosed embodiments are intended only as examples. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the aspects herein in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of possible implementations. Various embodiments are shown in, but the embodiments are not limited to the illustrated structure or application.

The terms “a” and “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The phrase “at least one of . . . and . . . ,” as used herein, refers to and encompasses any and all possible combinations of one or more of the associated listed items. As an example, the phrase “at least one of A, B, and C” includes A only, B only, C only, or any combination thereof (e.g., AB, AC, BC, OR ABC).

In this description, uses of “front,” “forward,” and the like, and uses of “rear,” “rearward,” and the like, refer to the longitudinal directions of the vehicle. “Front,” “forward,” and the like refer to the front (fore) of the vehicle, while “rear,” “rearward,” and the like refer to the back (aft) of the vehicle. Uses of “side,” “sideways,” “transverse,” and the like refer to the lateral directions of the vehicle. Uses of “above,” “below,” and the like refer to the vertical directions of the vehicle.

In this description, in one arrangement, the compartments of the vehicle include a passenger compartment, an engine compartment, a cargo area, and the like. Among other things, in one arrangement, the vehicle includes seats, a dash assembly, an instrument panel, controls, and the like housed in the passenger compartment. Additionally, in some instances, the vehicle may include an engine, a motor, a transmission, and the like, as well as other powertrain components, such as wheels, housed in the engine compartment and elsewhere in the vehicle. The wheels support the remainder of the vehicle on the ground. One, some or all of the wheels are powered by the remainder of the powertrain components to drive the vehicle along the ground.

Aspects herein can be embodied in other forms without departing from the spirit or essential attributes thereof. Accordingly, reference should be made to the following claims, rather than to the foregoing specification, as indicating the scope thereof.